Binder for non-woven fabric

ABSTRACT

This invention relates to fire retardant latex binders for non-woven fabrics. Non-woven fabrics can be manufactured using the fire retardant latex binder formulations of this invention using cotton fibers, polyester fibers, rayon fibers, nylon fibers, cellulosic fibers, fiber glass or various mixtures of such fibers. The fire retardant latex binders of this invention are particularly useful in manufacturing fiber glass furnace filters. The fire retardant latex binders of this invention are comprised of (1) water, (2) a styrene-butadiene rubber, (3) a fatty acid soap, (4) a sulfonate surfactant, (5) an ethylene oxide/propylene oxide/ethylene oxide triblock polymer, wherein the ethylene oxide/propylene oxide/ethylene oxide triblock polymer has a number average molecular weight of at least 8000, and (6) about 10 phr to about 50 phr of diammonium phosphate.

FIELD OF THE INVENTION

[0001] This invention relates to fire-retardant latices which are usefulas binders for manufacturing non-woven fabrics. The fire-retardant latexbinders of this invention are particularly useful in manufacturingnon-woven fiberglass furnace filters.

BACKGROUND OF THE INVENTION

[0002] Various latex compositions can be used as binders for non-wovenfabrics. In many applications, it is desirable for the latex bindercomposition to provide fire-retardant characteristics. For instance, inclothing and household applications, it is normally desirable for thelatex employed to contain a fire-retardant material.

[0003] A wide variety of chemical agents can be used in latex binders asfire-retardants. For instance, tris-(2,3-dibromopropyl) phosphate wasonce widely used as a flame-retardant in manufacturing children'ssleepwear. However, tris-(2,3-dibromopropyl) phosphate is no longer usedin such applications because testing has showed that it might becarcinogenic. Other flame-retardant compounds that have been developedto replace tris-(2,3-dibromopropyl) phosphate includetris(1,3-dichloroisopropyl) phosphate and a mixture of two cyclicphosphonate esters.

[0004] U.S. Pat. No. 2,036,854 discloses that a mixture of ammoniumborate or phosphate with an ammonium halide, such as ammonium bromide,is useful for flame-proofing textile materials. U.S. Pat. No. 2,036,854further reports that the ammonium halide appears to greatly enhance theflame-extinguishing properties of the ammonium borate or phosphate.

[0005] U.S. Pat. No. 2,452,054 discloses the use of diammonium phosphateand ammonium bromide as a flame-retardant for use on cellulosicmaterials. It is further disclosed in U.S. Pat. No. 3,061,492 thatammonium bromide can be used as a flame-retardant for unsaturatedpolyester resin compositions.

[0006] U.S. Pat. No. 3,840,488 discloses the use of ammonium bromide andurea as flame-retardant additives for styrene-butadiene rubber (SBR)latex that is used for textile treatment and carpet backingapplications. However, U.S. Pat. No. 3,840,488 further discloses thatthe utilization of ammonium bromide and urea in such latices has theundesirable effect of reducing the viscosity of the latex. The teachingsof U.S. Pat. No. 3,840,488 further indicate that this undesirabledecrease in the viscosity of the latex can be prevented by the additionof a halo alkyl phosphoric acid or salt.

[0007] U.S. Pat. No. 5,484,839 discloses a flame-retardant natural orsynthetic latex which is grafted with ring-halogenated, ethylenicallyunsaturated aromatic monomers. These grafted latex compositions arereported to be useful as non-woven filter media binders, as backcoatingsfor woven upholstery and draperies, and in other applications.

[0008] U.S. Pat. No. 4,239,670 appreciates the fact that the addition ofsome flame-retardant materials, such as diammonium phosphate, to latexcan cause the latex to become unstable. U.S. Pat. No. 4,239,670 furthernotes that such instability can render the latex unsuitable for itsintended purpose. U.S. Pat. No. 4,239,670 solves the problem of latexinstability caused by the addition of diammonium phosphate by furtheradding one part by weight of ammonium bromide per part by weight ofdiammonium phosphate added to the latex.

SUMMARY OF THE INVENTION

[0009] It has been unexpectedly found that the stability ofstyrene-butadiene rubber latices containing diammonium phosphate can besignificantly improved by adding from 0.1 phr (parts per 100 parts byweight of dry rubber) to 5 phr of a sulfonate surfactant and 0.1 phr to4 phr of an ethylene oxide/propylene oxide/ethylene oxide triblockpolymer nonionic surfactant thereto. By utilizing this techniquefire-retardant latex binder compositions containing diammonium phosphatecan be made without the need to add ammonium bromide to attain asatisfactory level of stability. Since diammonium phosphate can beincluded in the latex composition, it is not necessary to graft aring-halogenated, ethylenically unsaturated aromatic monomer onto thelatex composition to render it fire-retardant.

[0010] The present invention specifically discloses a fire-retardantlatex binder composition which is comprised of (1) water, (2) astyrene-butadiene rubber, (3) a fatty acid soap, (4) a sulfonatesurfactant, (5) an ethylene oxide/propylene oxide/ethylene oxidetriblock polymer, wherein the ethylene oxide/propylene oxide/ethyleneoxide triblock polymer has a number average molecular weight of at least8000, and (6) about 10 phr to about 50 phr of diammonium phosphate. Thisfire-retardant latex binder composition is particularly useful as abinder for manufacturing non-woven fabric.

[0011] The present invention further discloses a process formanufacturing a furnace filter which comprises (I) applying afire-retardant latex binder composition to a fiberglass matrix toproduce a latex-coated fiberglass matrix, wherein the fire-retardantlatex binder composition is comprised of (1) water, (2) astyrene-butadiene rubber, (3) a fatty acid soap, (4) a sulfonatesurfactant, (5) an ethylene oxide/propylene oxide/ethylene oxidetriblock polymer, wherein the ethylene oxide/propylene oxide/ethyleneoxide triblock polymer has a number average molecular weight of at least8000, and (6) about 10 phr to about 50 phr of diammonium phosphate, and(II) drying the latex coated fiberglass matrix to produce the furnacefilter.

DETAILED DESCRIPTION OF THE INVENTION

[0012] The fire-retardant latex binder compositions of this inventionare made by simply mixing about 10 phr (parts per hundred parts byweight of rubber) to about 50 phr of diammonium phosphate into astyrene-butadiene latex that contains a fatty acid soap, a sulfonatesurfactant and an ethylene oxide/propylene oxide/ethylene oxide triblockpolymer, wherein the ethylene oxide/propylene oxide/ethylene oxidetriblock polymer has a number average molecular weight of at least 8000.Such a latex is manufactured and sold by The Goodyear Tire & RubberCompany under the name Pliolite® 5000C. In most cases, from about 15 phrto about 40 phr of diammonium phosphate will be mixed into the latex.

[0013] Such styrene-butadiene rubbers in the latex is comprised ofrepeat units which are derived from styrene monomer and 1,3-butadienerubber. Such styrene-butadiene rubbers will typically be comprised ofrepeat units which are derived from about 1 to about 40 weight percentstyrene and about 60 to about 99 weight percent butadiene. Thestyrene-butadiene rubber in the latex will typically contain from about10 weight percent to about 30 styrene and from about 70 weight percentto about 90 weight percent butadiene. The styrene-butadiene rubber inthe latex will more preferably contain about 15 weight percent to about25 weight percent styrene and from about 75 weight percent to about 85weight percent butadiene.

[0014] The styrene-butadiene rubber latex can be synthesized using afatty acid soap system and conventional emulsion polymerizationtechniques. Such emulsion polymerizations generally utilize a chargecomposition which is comprised of water, styrene monomer, 1,3-butadienemonomer, an initiator and a fatty acid soap. Such polymerizations can beconducted over a very wide temperature range from about 0° C. to as highas about 100° C. Such emulsion polymerizations are typically conductedat a temperature which is within the range of about 5° C. to about 60°C.

[0015] The fatty acid soap used in such polymerizations may be chargedat the outset of the polymerization or may be added incrementally orproportionately as the reaction proceeds. Normally, from about 2 phm(parts by weight per 100 parts by weight of monomer) to about 7 phm ofthe fatty acid soap will be charged into the polymerization medium. Itis typically preferred for the polymerization medium to contain fromabout 4 phm to about 6 phm of the fatty acid soap.

[0016] The emulsion polymerizations used in synthesizing thestyrene-butadiene rubber latex may be initiated using free radicalcatalysts, ultraviolet light or radiation. To insure a satisfactorypolymerization rate, uniformity and a controllable polymerization, freeradical initiators are virtually always used to initiate such emulsionpolymerizations. Free radical initiators which are commonly used includethe various peroxygen compounds such as potassium persulfate, ammoniumpersulfate, benzoyl peroxide, hydrogen peroxide, di-t-butylperoxide,dicumyl peroxide, 2,4-dichlorobenzoyl peroxide, decanoyl peroxide,lauroyl peroxide, cumene hydroperoxide, p-menthane hydroperoxide,t-butylhydroperoxide, acetyl acetone peroxide, methyl ethyl ketoneperoxide, succinic acid peroxide, dicetyl peroxydicarbonate, t-butylperoxyacetate, t-butyl peroxymaleic acid, t-butyl peroxybenzoate,t-butyl peroxymaleic acid, t-butyl peroxybenzoate, acetyl cyclohexylsulfonyl peroxide, and the like; the various azo compounds such as2-t-butylazo-2-cyanopropane, dimethyl azodiisobutyrate,azodiisobutyronitrile, 2-t-butylazo-1-cyanocyclohexane,1-t-amylazo-1-cyanocyclohexane, and the like; the various alkylperketals, such as 2,2-bis-(t-butylperoxy)butane, ethyl3,3-bis(t-butylperoxy)butyrate, 1,1-di-(t-butylperoxy)cyclohexane, andthe like.

[0017] The emulsion polymerization system used in the synthesis of thelatex can be treated at the desired degree of conversion withshortstopping agents, such as hydroquinone or a combination of thesodium salt of N,N-dimethyl dithiocarbamate with N,N-diethylhydroxylamine. Typical stabilizing agents and standard antioxidants canalso be added to the latex.

[0018] In accordance with this invention, from about 0.1 phr to 5 phr ofa sulfonate surfactant and from about 0.1 phr to about 4 phr of anethylene oxide/propylene oxide/ethylene oxide block terpolymer will beadded latex. It is typically preferred to add 1 phr to 3 phr of thesulfonate surfactant and 0.4 phr to 2 phr of the ethyleneoxide/propylene oxide/ethylene oxide block terpolymer to thestyrene-butadiene latex. It is typically more preferred to add 1.5 phrto 2.5 phr of the sulfonate surfactant and 0.8 phr to 1.2 phr of theethylene oxide/propylene oxide/ethylene oxide block terpolymer to thestyrene-butadiene latex.

[0019] Some representative examples of sulfonate surfactants that can beemployed include: alkane sulfonates, esters and salts (such asalkylchlorosulfonates) and alkylsulfonates with the general formula:

RSO₃H

[0020] wherein R is an alkyl group having from 1 to 20 carbon atoms;sulfonates with intermediate linkages such as ester and ester-linkedsulfonates such as those having the formula:

RCOOC₂H₄SO₃H

[0021] and

ROOC—CH₂—SO₃H

[0022] wherein R is an alkyl group having from 1 to 20 carbon atoms suchas dialkyl sulfosuccinates; ester salts with the general formula:

[0023] wherein R is an alkyl group having from 1 to 20 carbon atoms,alkarylsulfonates in which the alkyl groups contain preferably from 10to 20 carbon atoms (e.g., dodecylbenzenesulfonates, such as sodiumdodecylbenzenesulfonate) and alkyl phenol sulfonates.

[0024] Disulfonated surfactants having the structural formula:

[0025] wherein R represents a linear or branched alkyl group containingfrom about 6 to about 16 carbon atoms and wherein X represents a metalion, such as a sodium ion, have proven to be excellent surfactants formaking the latex used in the practice of this invention. Suchsurfactants are sold by The Dow Chemical Company as Dowfax™ anionicsurfactants.

[0026] The ethylene oxide/propylene oxide/ethylene oxide triblockpolymers that can be used are of the structural formula:

[0027] These triblock polymers will typically have a number averagemolecular weight of at least 8000. The triblock polymer will typicallyhave a number average molecular weight which is within the range ofabout 10,000 to about 20,000. It is normally preferred for the triblockpolymer to have a number average molecular weight which is within therange of 10,500 to 16,000. It is typically more preferred for thetriblock polymer to have a number average molecular weight which iswithin the range of 11,000 to 14,000.

[0028] The polyoxypropylene block in the triblock polymer will typicallyhave a number average molecular weight which is within the range ofabout 2,000 to about 12,000 and will more typically have a numberaverage molecular weight which is within the range of 2,500 to 8,000.The polyoxypropylene block in the triblock polymer will preferably havea number average molecular weight which is within the range of 3,000 to6,000. The polyoxypropylene block in the triblock polymer will morepreferably have a number average molecular weight which is within therange of 3,500 to 4,500.

[0029] The polyoxyethylene blocks in the triblock polymer will typicallycomprise 50 weight percent to 90 weight percent of the total weight ofthe triblock polymer (the polyoxypropylene blocks will, of course,comprise the remaining 10 weight percent to 50 weight percent of thetriblock polymer). The polyoxyethylene blocks in the triblock polymerwill preferably comprise 60 weight percent to 80 weight percent of thetotal weight of the triblock polymer with the polyoxypropylene blockscomprising the remaining 20 weight percent to 40 weight percent of thetriblock polymer. The polyoxyethylene blocks in the triblock polymerwill preferably comprise 70 weight percent to 75 weight percent of thetotal weight of the triblock polymer with the polyoxypropylene blockscomprising the remaining 25 weight percent to 30 weight percent of thetriblock polymer. It is preferred for the triblock polymer to have a HLB(hydrophilic/lipophilic balance) number which is within the range ofabout 18 to about 26. It is more preferred for the triblock polymer tohave a HLB number which is within the range of 18 to 23. Pluronic® F108surfactant and Pluronic® F127F surfactant are representative examples ofethylene oxide/propylene oxide/ethylene oxide triblock polymers that canbe used in making the fire-retardant latex binder compositions of thisinvention.

[0030] The fire-retardant latex binder compositions of this inventioncan be employed as a binder for manufacturing a wide variety ofnon-woven fabrics. For example, non-woven fabrics can be manufacturedusing the fire retardant latex binder formulations of this inventionusing cotton fibers, polyester fibers, rayon fibers, nylon fibers,cellulosic fibers, fiber glass or various mixtures of such fibers. Thefire retardant latex binders of this invention are particularly usefulin manufacturing fiber glass furnace filters.

[0031] The fire-retardant latex binder compositions of this inventioncan be applied to substrates in manufacturing non-woven fabrics usingany method known in the art. For instance, the fire-retardant latexbinder composition can be applied to unwoven substrate fibers by kissrolling, knife coating, airless spray or padding. Irrespective of whichmethod of application is used, the latex binder which has been appliedto the fibers needs to be dried or cured. This drying step is normallyconducted by heating the fibers at an elevated temperature for a shortperiod of time which is sufficient to effect drying and a proper cure.The temperature used in the drying step will typically be within therange of about 80° C. to about 160° C. and will more typically be withinthe range of about 110° C. to about 140° C.

[0032] Fiberglass is typically used in manufacturing furnace filterssince the fiber can experience high temperatures during periods of itsnormal service life. In manufacturing such furnace filters, thefire-retardant latex binder is normally sprayed onto a fiberglass matrixof the desired size and shape. The binder will be applied at a levelwhich is sufficient to penetrate the fiberglass matrix. After the binderhas been applied to the fiberglass matrix, the latex-coated matrix isdried using a conventional procedure. For instance, dry air can becirculated through the latex-coated fiberglass matrix at an elevatedtemperature which is within the range of about 100° C. to about 150° C.

[0033] This invention is illustrated by the following examples which aremerely for the purpose of illustration and are not to be regarded aslimiting the scope of the invention or the manner in which it can bepracticed. Unless specifically indicated otherwise, parts andpercentages are given by weight.

COMPARATIVE EXAMPLE 1

[0034] In this experiment, 20 phr of diammonium phosphate was added to abottle of Pliolite® 5356 styrene-butadiene rubber latex that hadpreviously been diluted with water to a solids content of about 33percent. The Pliolite® 5356 styrene-butadiene latex used was emulsifiedwith a fatty acid soap, had a bound styrene content of about 23.5percent, an original solids content of about 70 percent, a Brookfieldviscosity of about 1400 cps and had a Mooney viscosity of 100. However,upon the addition of the diammonium phosphate, the latex became unstableand coagulated.

EXAMPLE 2

[0035] In this experiment, 2 phr of Dowfax® 8390 sulfonate surfactantand 1 phr of Pluronic® F127Ppolyoxyethylene-polyoxypropylene-polyoxyethylene nonionic surfactant wasadded to Pliolite® 8390 styrene-butadiene rubber latex. Then, 20 phr ofdiammonium phosphate was added to the latex. The latex remained stableand coagulation did not occur.

EXAMPLE 3

[0036] In this experiment, 2 phr of Dowfax® 8390 sulfonate surfactantand 1 phr of Pluronic® F127Ppolyoxyethylene-polyoxypropylene-polyoxyethylene nonionic surfactant wasadded to Pliolite® 8390 styrene-butadiene rubber latex. Then, 40 phr ofdiammonium phosphate was added to the latex. The latex remained stableand coagulation did not occur. This experiment shows that the additionof the combination of the sulfonate surfactant and thepolyoxyethylene-polyoxypropylene-polyoxyethylene nonionic surfactantcaused the latex to remain stable even in the case where the diammoniumphosphate was added at a very high level.

EXAMPLE 4

[0037] A fire-retardant latex binder composition can be made by mixing25 phr of diammonium phosphate into Pliolite® 5000C styrene-butadienerubber latex. Then, a non-woven polyester sheet can be manufactured byfirst passing loose polyester fibers through a garnet sizer and thenspraying the non-woven polyester sheet produced in the garnet sizer withthe latex containing the diammonium phosphate. Then, the wet non-wovenpolyester sheet can be slowly passed through an oven at a temperature of300° F. (149° C.). The dried bonded fiber can then be rolled andpackaged.

EXAMPLE 5

[0038] In this example, one liter of Pliolite® 5000C styrene-butadienelatex is diluted with 4 liters of water and 25 phr of diammoniumphosphate is added to the diluted latex. The diluted latex solution isthen mixed with cellulose paper fiber for application to a substrate.Typically, the mixture is applied to walls or ceilings as insulation.The latex and cellulose can be applied to any suitable substrate byusing a sprayer. The substrate coated with 2-5 cm of insulation coatingcan then be left to dry at room temperature over a period of about 3 to7 days. This technique is known as the “cellulose fiber method.”

EXAMPLE 6

[0039] A fire-retardant latex binder composition can be made by mixing40 phr of diammonium phosphate into Pliolite® 5000C styrene-butadienerubber latex. The fire-retardant latex binder composition can then beused in manufacturing furnace filters. In such a procedure, a fiberglassfurnace filter matrix of the desired size and shape is prepared. Then,the latex binder composition can be applied with a fly sprayer onto bothsides on the non-woven fiberglass matrix at a level of about 25 weightpercent (dry weight). Then, the latex binder coated fiberglass matrix isdried by passing it through an oven dryer that is maintained at atemperature of about 150° C. The furnace filters produced by thistechnique will have outstanding fire-retardant capacity.

[0040] While certain representative embodiments and details have beenshown for the purpose of illustrating the subject invention, it will beapparent to those skilled in this art that various changes andmodifications can be made therein without departing from the scope ofthe subject invention.

What is claimed is:
 1. A fire-retardant latex binder composition whichis comprised of (1) water, (2) a styrene-butadiene rubber, (3) a fattyacid soap, (4) a sulfonate surfactant, (5) an ethylene oxide/propyleneoxide/ethylene oxide triblock polymer, wherein the ethyleneoxide/propylene oxide/ethylene oxide triblock polymer has a numberaverage molecular weight of at least 8000, and (6) about 10 phr to about50 phr of diammonium phosphate.
 2. A fire-retardant latex bindercomposition as specified in claim 1 wherein the sulfonate surfactant ispresent at a level which is within the range of about 0.1 phr to about 5phr, and wherein the ethylene oxide/propylene oxide/ethylene oxidetriblock polymer is present at a level which is within the range ofabout 0.1 phr to about 4 phr.
 3. A fire-retardant latex bindercomposition as specified in claim 2 wherein the latex binder compositioncontains from about 2 phr to about 7 phr of the fatty acid soap.
 4. Afire-retardant latex binder composition as specified in claim 3 whereinthe styrene-butadiene rubber contains repeat units that are derived fromabout 10 weight percent to about 30 weight percent styrene and fromabout 70 weight percent to about 90 weight percent 1,3-butadiene.
 5. Afire-retardant latex binder composition as specified in claim 4 whereinthe ethylene oxide/propylene oxide/ethylene oxide triblock polymer has apropylene oxide block that has a number average molecular weight whichis within the range of 2,000 to 12,000.
 6. A fire-retardant latex bindercomposition as specified in claim 5 wherein propylene oxide block in theethylene oxide/propylene oxide/ethylene oxide triblock polymer has amolecular weight that represents from 10 weight percent to 50 weightpercent of the total molecular weight of the triblock polymer.
 7. Afire-retardant latex binder composition as specified in claim 6 whereinthe sulfonate surfactant is present at a level which is within the rangeof about 1 phr to about 3 phr, and wherein the ethylene oxide/propyleneoxide/ethylene oxide triblock polymer is present at a level which iswithin the range of about 0.4 phr to about 2 phr.
 8. A fire-retardantlatex binder composition as specified in claim 7 wherein the latexcontains from about 4 phr to about 6 phr of the fatty acid soap.
 9. Afire-retardant latex binder composition as specified in claim 8 whereinthe ethylene oxide/propylene oxide/ethylene oxide triblock polymer has anumber average molecular weight which is within the range of 10,000 to20,000.
 10. A fire-retardant latex binder composition as specified inclaim 9 wherein the ethylene oxide/propylene oxide/ethylene oxidetriblock polymer has a propylene oxide block that has a number averagemolecular weight which is within the range of 2,500 to 8,000.
 11. Afire-retardant latex binder composition as specified in claim 10 whereinpropylene oxide block in the ethylene oxide/propylene oxide/ethyleneoxide triblock polymer has a molecular weight that represents from 20weight percent to 40 weight percent of the total molecular weight of thetriblock polymer.
 12. A fire-retardant latex binder composition asspecified in claim 11 wherein the diammonium phosphate is present at alevel which is within the range of about 15 phr to about 40 phr.
 13. Afire-retardant latex binder composition as specified in claim 12 whereinthe sulfonate surfactant is present at a level which is within the rangeof about 1.5 phr to about 2.5 phr, and wherein the ethyleneoxide/propylene oxide/ethylene oxide triblock polymer is present at alevel which is within the range of about 0.8 phr to about 1.2 phr.
 14. Afire-retardant latex binder composition as specified in claim 13 whereinthe ethylene oxide/propylene oxide/ethylene oxide triblock polymer has anumber average molecular weight which is within the range of 10,500 to16,000.
 15. A fire-retardant latex binder composition as specified inclaim 14 wherein the ethylene oxide/propylene oxide/ethylene oxidetriblock polymer has a propylene oxide block that has a number averagemolecular weight which is within the range of 3,000 to 6,000.
 16. Afire-retardant latex binder composition as specified in claim 15 whereinthe ethylene oxide/propylene oxide/ethylene oxide triblock polymer has anumber average molecular weight which is within the range of 11,000 to14,000.
 17. A fire-retardant latex binder composition as specified inclaim 16 wherein propylene oxide block in the ethylene oxide/propyleneoxide/ethylene oxide triblock polymer has a molecular weight thatrepresents from 25 weight percent to 30 weight percent of the totalmolecular weight of the triblock polymer.
 18. A fire-retardant latexbinder composition as specified in claim 16 wherein thestyrene-butadiene rubber contains repeat units that are derived fromabout 15 weight percent to about 25 weight percent styrene and fromabout 75 weight percent to about 85 weight percent 1,3-butadiene.
 19. Aprocess for manufacturing a furnace filter which comprises (I) applyinga fire-retardant latex binder composition to a fiberglass matrix toproduce a latex-coated fiberglass matrix, wherein the fire-retardantlatex binder composition is comprised of (1) water, (2) astyrene-butadiene rubber, (3) a fatty acid soap, (4) a sulfonatesurfactant, (5) an ethylene oxide/propylene oxide/ethylene oxidetriblock polymer, wherein the ethylene oxide/propylene oxide/ethyleneoxide triblock polymer has a number average molecular weight of at least8000, and (6) about 10 phr to about 50 phr of diammonium phosphate, and(II) drying the latex-coated fiberglass matrix to produce the furnacefilter.
 20. A process as specified in claim 19 wherein the sulfonatesurfactant is present at a level which is within the range of about 0.1phr to about 5 phr, wherein the ethylene oxide/propylene oxide/ethyleneoxide triblock polymer is present at a level which is within the rangeof about 0.1 phr to about 4 phr, wherein the fatty acid soap is presentat a level which is within the range of about 2 phr to about 7 phr, andwherein the diammonium phosphate is present at a level which is withinthe range of about 15 phr to about 40 phr.
 21. A process as specified inclaim 20 wherein the fire-retardant latex binder composition is sprayedonto the fiberglass matrix and wherein the latex coated fiberglassmatrix is dried at a temperature which is within the range of about 110°C. to about 150° C.